Mitsubishi L200. Manual — part 251
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-29
INPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222001600526
AK500516
Apply gear oil to
all moving parts
before installation.
AB
1
2
5
3
4
Disassembly steps
>>
B
<<
1.
Shaft snap ring
<<
A
>>
>>
A
<<
2.
Radial ball bearing
3.
Synchronizer ring No.2
4.
Needle roller bearing
5.
Input shaft sub-assembly
DISASSEMBLY SERVICE POINT
<<A>> RADIAL BALL BEARING REMOVAL
AK403995
AC
MD998801
Using special tool Bearing remover (MD998801),
support the radial ball bearing and remove it.
REASSEMBLY SERVICE POINTS
>>A<< RADIAL BALL BEARING INSTALLATION
AK500606AB
Installation
direction
1. Check the installation direction of the radial ball
bearing, and put it on the input shaft.
CAUTION
Never push on the sealing area when installing.
AK403996
MD998812
AB
MD998823
MD998814
INPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-30
2. Using special tools to install the radial ball
bearing.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
>>B<< SNAP RING INSTALLATION
AK403997
1. Select a snap ring to secure the standard
clearance between the radial ball bearing and the
input shaft sub-assembly.
Standard value: 0
− 0.1 mm
2. Install the selected snap ring.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY
AK500677AB
1. Check the helical gear teeth and clutch gear teeth
of each input shaft sub-assembly for damage and
excessive wear.
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage,
and excessive wear.
3. Check the inside surface and front and back sides
of each input shaft sub-assembly for damage and
excessive wear.
SYNCHRONIZER RING No.2
AK500676AB
1. Check the clutch gear on the synchronizer ring for
damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
ridges are intact.
AK403998
3. After applying oil to the taper portion on gear,
press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK403999
4. Using the thickness gauge, check the clearance
between the synchronizer ring and the 4th gear.
Standard value: 0.70
− 1.70 mm
Minimum limit: 0.70 mm
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-31
2. Check the needle roller bearing cage for
deformation.
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002100160
AK500517
Apply gear oil to
all moving parts
before installation.
AB
1
2
3
4
5
8
7
6
9
10
11
14
12
15
16
17
13
26
25
24
18
19
21
22
20
23
Disassembly steps
>>
G
<< 1.
Shaft snap ring
<<
A
>>
>>
F
2.
5th gear
<<
B
>>
>>
E
3.
Radial ball bearing
<<
B
>>
>>
E
4.
1st gear sub-assembly
5.
1st gear thrust washer
6.
Straight pin
7.
Needle roller bearing
8.
D spacer
9.
Synchronizer ring set No.1
>>
D
<<
10. Shaft snap ring
<<
C
>>
>>
C
<<
11. Reverse gear
<<
C
>>
>>
C
<<
12. Synchronizer shifting key No.1
<<
C
>>
>>
C
13. Compression spring
<<
C
>>
>>
C
14. Transmission clutch No.1 hub
<<
C
>>
>>
C
15. Synchronizer ring set No.1
<<
C
>>
>>
C
16. 2nd gear sub-assembly
17. Needle roller bearing
>>
B
18. Shaft snap ring
<<
D
>>
>>
A
19. Transmission hub sleeve No.2
<<
D
>>
>>
A
20. Synchronizer shifting key No.2
<<
D
>>
>>
A
21. Compression spring
<<
D
>>
>>
A
22. Transmission clutch No.2 hub
<<
D
>>
>>
A
23. Synchronizer ring set No.2
<<
D
>>
>>
A
24. 3rd gear sub-assembly
Disassembly steps (Continued)
OUTPUT SHAFT
MANUAL TRANSMISSION OVERHAUL <R5MB1>
22B-32
INSPECTION BEFORE DISASSEMBLY
THRUST CLEARANCE FOR EACH GEAR
AK404000
AB
2nd
3rd
1st
Inspect the thrust clearance of each gear.
Gear
Standard value mm
Limit mm
1st
0.20
− 0.45
0.45
2nd
0.10
− 0.25
0.25
3rd
0.10
− 0.25
0.25
RADIAL CLEARANCE FOR EACH GEAR
AK404001
AB
1. Fix the output shaft by a vice.
2. Inspect the radial clearance of each gear.
Gear
Standard value mm
Limit mm
1st
0.020
− 0.073
0.073
2nd
0.015
− 0.068
0.068
3rd
0.015
− 0.068
0.068
DISASSEMBLY SERVICE POINTS
<<A>> 5TH GEAR REMOVAL
AK404004
MD998801
AB
Using special tool Bearing remover (MD998801),
support the 5th gear and remove it.
<<B>> RADIAL BALL BEARING / 1ST GEAR SUB-
ASSEMBLY REMOVAL
AK404006
MD998801
AB
Using special tool Bearing remover (MD998801),
support the 1st gear sub-assembly and remove the
radial ball bearing and the 1st gear sub-assembly.
<<C>> REVERSE GEAR / SYNCHRONIZER
SHIFTING KEY No.1 / COMPRESSION SPRING /
TRANSMISSION CLUTCH No.1 HUB /
SYNCHRONIZER RING SET No.1 / 2ND GEAR
SUB-ASSEMBLY REMOVAL
AK404014
MD998801
AB
Using special tool Bearing remover (MD998801),
support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No.1, com-
pression spring, the transmission clutch No.1 hub,
synchronizer ring set No.1 and the 2nd gear sub-
assembly.
25. Needle roller bearing
26. Output shaft
Disassembly steps (Continued)
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